I agree, small crossing are normally the best.
USA - Mexico: Recommend avoiding Laredo. Go for Nogales or Naco to get into Mexico.
Mexico - Guat: La Mesilla better than Tapachula
Guat - Honduras: Avoid Aguas Calientes like plague. Go for Copan Ruinas
Hond - Nic: Only ever done main Pan Am route. Busy but OK.
Nic - Costa Rica: ditto
Costa Rica - Pan: mmm - north route is definitely more interesting and involves the banana bridge at the border and also a second bridge about 10 miles down the road (where the train DOES run!). But much more fun that the main Pan Am.
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